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Corrosion Control Survey Methods

for Offshore
Pipelines and Structures
by
Clark P. Weldon

and
David H. Kroon, P.E.
Vice President of Engineering
CORRPRO Companies, Inc.
Construction and operation of offshore production fa- form risers, wellheads, and test stations located near
cilities is tremendously expensive. The consequences shore. Divers can be used to take potential measure-
of an offshore corrosion failure can be devastating. For ments on unburied pipelines, but this procedure is much
these reasons, cathodic protection has become a uni- too costly to use extensively.
versally applied technique for mitigating corrosion on
marine pipeline and production facilities. Monitoring of pipeline cathodic protection only at plat-
forms or shore installations provides limited informa-
Marine pipelines are typically provided with cathodic tion. It is possible that serious corrosion can be occur-
protection by bracelet anodes of zinc or aluminum. Im- ring on a pipeline even when potentials at a riser or test
pressed current systems at platforms or onshore are station satisfy the criteria for cathodic protection.
also used, as well as hybrid systems which employ a
combination of the two techniques. For marine struc- In many respects, the same is true for platforms. Po-
tures, aluminum anodes are often attached to the jacket, tential measurements taken from the surface frequently
although impressed current and hybrid systems are also do not reflect the significant data necessary for com-
common. prehensive evaluation of the cathodic protection sys-
tem. In many cases, areas of low potential indicating
Whatever the method of applying cathodic protection, lack of protection are highly localized at nodes, con-
the primary concern is arresting corrosion. For cathodic ductor bays or skirt pile guides. These anomalies would
protection to be effective in arresting corrosion, a prop- typically not be detected unless a detailed inspection
erly planned program of monitoring, inspection and and potential survey was performed.
maintenance is essential.
Corrosion surveys and inspection of offshore platforms
The most widely accepted method of evaluating ca- and pipelines are particularly important at this stage in
thodic protection on pipelines and structures is through development of our offshore petroleum resources. Many
the use of potential measurements. Potential measure- existing offshore platforms and pipelines are reaching
ments on offshore pipelines have traditionally been re- the end of their cathodic protection system design lives.
corded only at readily accessible locations such as plat- Decisions must be made as to if and/or when additional

Corrpro Companies, Inc. Technical Paper 4 Page 1 of 10


Figure 1 Towed Fish/Trailing Wire Survey

cathodic protection must be retrofitted to prevent cor- Towed Vehicle/Trailing Wire Pipeline Survey
rosion failures. The data provided by corrosion surveys The Towed Vehicle/Trailing Wire potential survey is
and inspection plays a key role in this decision making probably the most widely used method for monitoring
process. cathodic protection levels along offshore pipelines. The
survey is performed by making a test connection to the
The industry move into “deep” water has also had a pipeline at an accessible location such as an offshore
tremendous impact on corrosion control practices. Deep platform riser or onshore test station. Alternately, the
water platforms and pipelines present new challenges survey may be performed with a test connection to a
for design, maintenance, inspection and retrofit of cor- stationary electrode placed on the sea floor at a loca-
rosion control systems. The advent of the remotely op- tion where the pipeline potential is known. A silver/sil-
erated vehicle (ROV) has radically altered corrosion ver chloride reference electrode is towed above the
survey and inspection practices. pipeline from a vessel while maintaining the test con-
nection. The pipe-to-electrolyte (P/E) potential is mea-
Probably the single most important development in the sured and recorded on board with a computerized data
last several years with respect to offshore corrosion acquisition system. The potential is displayed on a video
survey and inspection methods is the use of computers terminal and plotted on a graphics printer’ (see Figure
Computerization of survey data acquisition, processing 1).
and management has provided the means for develop-
ment of all of the state of the art corrosion control tech- The pipeline is generally tracked by electronic position-
niques used today. These include close interval pipeline ing equipment in conjunction with as-built coordinates.
surveys, modeling of platform cathodic protection and Side scan sonar or marine magnetometers can be used,
inspection data management systems. particularly when the accuracy of the as-built coordi-
nates is in question, or is not available.
The purpose of this paper is to present an overview of
corrosion control survey techniques in use today for The foremost objective of this survey is to determine
monitoring and maintenance of offshore pipelines and the general level of cathodic protection relative to the
platforms. The paper also includes a discussion of com- NACE. criterion of -800 millivolts to Ag/AgCl. Figure
puterized inspection data management techniques. 2 shows a typical P/E potential profile. Study of the

Corrpro Companies, Inc. Technical Paper 4 Page 2 of 10


profile indicates adequate cathodic protection with the The primary disadvantage is lack of sensitivity to minor
exception of approximately 4000 feet of pipeline cen- anomalies such as individual anode bracelets, small coat-
tered at seven thousand feet from the platform. Poten- ing defects, and poorly insulated field joints. On a well
tial values recorded on this section are more positive polarized pipeline, anomalies such as these can be de-
than the -800 millivolt criterion for cathodic protection. tected only when the reference electrode position is
A depression in potential value of this magnitude is typi- maintained at a distance of less than approximately two
cally caused by either severe coating damage or anode pipeline diameters from the pipeline.
depletion. The exact cause cannot be determined from
the potential profile alone.1 Submersible/Trailing Wire Pipeline Survey
This technique uses the same principles as the towed
The continuous towed vehicle survey can also provide vehicle survey, but a submersible is used to carry the
information to determine magnitude and direction of long reference electrode along the pipeline. Under normal
line currents, electrical interference, and current require- circumstances, the reference electrode position can be
ments. maintained within a meter of the pipeline at all times.
This makes it possible to detect features such as brace-
The towed vehicle/trailing wire survey is used to deter- let anodes and coating holidays that cannot be detected
mine the overall P/E potential profile and for location of using the towed vehicle method.
major problem areas such as areas of coating damage
or anode loss. The advantages are relatively low cost, Figure 3 illustrates the technique using an unmanned
when compared to submersible or diver assisted sur- submersible (remotely operated vehicle) to carry the
veys, and simplicity of theory and operation. Addition- reference electrode. Note that the R.O.V. is only used
ally, this is the only technique which can be used eco- as a vehicle for the reference electrode. All wire han-
nomically on buried pipelines and under other condi- dling and data acquisition are performed on board the
tions where visual or magnetic tracking with a diver or support vessel which is connected to the R.O.V. by a
R.O.V. is difficult to impossible. tether.2

Figure 2: P/E Potential Profile - Towed Fish Survey


-1200

-1100
POTENTIAL (Millivolts)

-1000

-900

-800

-700

-600
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000
DISTANCE (Feet)

Corrpro Companies, Inc. Technical Paper 4 Page 3 of 10


Figure 3 Unmanned Submersible Trailing Wire Survey

Reading location is typically determined using conven- The primary advantage of the submersible technique is
tional electronic surface positioning (ship location) in- the increased sensitivity to minor changes in potential.
terfaced with underwater acoustic positioning (ROV The survey provides a detailed P/E potential profile,
location). Reference points such as anode bracelets, pinpoints the location of problem areas, and provides
pipe joints, line crossings and risers serve as calibration information concerning the cause of a problem. The
points for the positioning systems. Position fixes are elec- submersible potential survey is ideally performed in con-
tronically entered into the cathodic protection survey junction with electric field gradient (cell-to-cell) mea-
data stream at fixed intervals and at anomalies. The sur- surements. This provides even greater resolution of
vey data is later plotted versus pipeline stationing to anomalies and aids in the interpretation of the P/E po-
provide a detailed continuous potential profile of a pipe- tential data.
line. This includes detection of individual bracelet an-
odes, coating holidays, and poorly coated or damaged The primary disadvantage of the submersible survey is
field joint wraps. A short section of typical data is shown relatively high cost per pipeline mile. The cost of a sub-
in Figure 4. Study of the data indicates the presence of mersible survey is approximately 7 to 10 times the cost
two functioning bracelet anodes and two poorly coated of the towed vehicle survey on a per mile basis. For this
field joints. reason, most submersible assisted cathodic protection
surveys are performed in conjunction with other work
requiring an ROV.

A particular disadvantage of the Submersible/Trailing


Wire technique is that the use of a trailing wire during an
ROV aided survey can be difficult. The survey
progresses by maintaining the position of the survey
Anode support vessel above the ROV as the vehicle travels
Field Joints along the pipeline. This maneuver called “live boating”
Figure 4: P/E Potential Profile-Submersible Assisted requires skillful interaction between the survey vessel
Survey captain, the navigators and the R.O.V. pilot. The trail-

Corrpro Companies, Inc. Technical Paper 4 Page 4 of 10


ing wire can further complicate this often delicate pro- The P/E potential at any particular point on the pipe is
cess particularly when weather conditions are poor. then the P/E potential recorded by direct contact, plus
the voltage offset between the close and remote elec-
Remote Electrode Submersible Survey trodes at the point of direct contact, minus the potential
The most commonly used submersible aided survey is between the remote and close electrodes at the par-
the remote electrode survey. This technique has been ticular point.
popular in the North Sea for nearly ten years and is
commonly used as a component of many pipeline in- The primary advantage of this method is its relative ease
spections or surveys. of operation. Unlike the trailing wire technique, the re-
mote electrode method has little or no effect on the ROV
The remote electrode submersible survey measures the “live boating” operation.
potential between a Ag/AgCl electrode positioned just
above the pipeline and a “remote” electrode located The primary disadvantage is that direct contact poten-
near the water’s surface above the pipeline. This mea- tial readings are required to establish the original volt-
surement is used in conjunction with direct contact P/E age offset and to recalibrate the measurements at fre-
potential measurements at anodes and other accessible quent intervals.
locations to produce a continuous P/E potential pro-
file. A schematic of the remote reference electrode sur- This is required because the remote cell is moving and
vey is shown in Figure 5. is subject to some potential drift or variation over time.
This requirement virtually excludes the use of the re-
At the start of a remote electrode survey, a direct con- mote electrode survey on pipelines that are continuously
tact P/E potential is measured at an accessible location buried over long distances, as is the case with many
such as a bracelet anode. Simultaneously, the potential pipelines in the Gulf of Mexico.
between the electrode close to the pipe and the remote
electrode mounted on the submersible umbilical is re- Electric Field Gradient Survey
corded. This establishes the fixed voltage offset be- Electric field gradient (E.F.G.) measurements are usu-
tween the pipe potential and remote earth The two elec- ally made in conjunction with potential measurements
trodes are then moved down the pipeline and the po- obtamed using an R.O.V. E.F.G. measurements are made
tential between the electrodes is continuously recorded. by measuring the potential of two electrodes placed at

Figure 5: Remote Electrode Survey

Corrpro Companies, Inc. Technical Paper 4 Page 5 of 10


a known distance apart in a plane perpendicular to the for determining anode life or P/E potential. E.F.G. mea-
pipeline. This is typically accomplished by mounting two surements are most valuable when used in conjunction
or more electrodes on a submersible, aligned so that with P/E potential surveys or with direct P/E potential
they are normal to the pipeline, as the ROV proceeds readings taken at frequent intervals along pipelines.
along the pipeline. The electrodes may be spaced from
a few inches apart to over two feet apart depending on Drop Line Platform Survey
the equipment. The most commonly used method for monitoring ca-
thodic protection levels on offshore platform jackets is
One operator uses a rotating “T sensor” with two elec- to lower a weighted Ag/AgCl reference electrode from
trodes to measure EFG The sensor is rotated to elimi- the platform deck and record structure-to-electrolyte
nate errors caused by electrode potential drift over the potential values at uniform intervals from the water sur-
course of a survey. The operator claims precision of up face to the sea floor. This procedure is generally re-
to 1 micro-volt/cm using this technique.3 peated at several representative locations on the plat-
form jacket. Electrical connection to the structure is
Electric field gradient measurements are used to detect made above the water line. The electrical connection
changes in current density and direction at all points should be made to a welded structural member and
along a pipeline. This allows detection of anomalies such should not be in the vicinity of welding activity.
as nonfunctioning anodes, coating holidays, and defec-
tive field joint wraps which may not be detected by P/E The chief advantage of this method is simplicity and low
potential measurements. EFG also provides data useful cost. The primary disadvantage of the drop line is lack
for estimation of current densities associated with an- of ability to control reference electrode position relative
odes (current output) and coating holidays. This infor- to the structure. This makes accurate interpretation of
mation can be used to predict cathodic protection sys- potential measurements extremely difficult and prevents
tem life and for design of future pipeline cathodic pro- useful correlation of data with previous surveys on the
tection systems. Please note, however, that due to the same platform.
complex nature of the pipeline environment and the EFG
measurement, accurate calculation of anode output is Guy Line Platform Survey
extremely difficult, if not impossible, using existing sur- The guy line platform survey employs a tensioned guy
vey techniques. A number of variables must be consid- wire which runs from the sea floor to the water surface
ered in this calculation including electrolyte resistivity, inside the platform jacket. A reference electrode is at-
degree of anode burial and anodesensor geometry. A tached to the guy wire and lowered to the bottom while
study performed in 1982 of the various methods for potential measurements are taken at selected intervals.
offshore pipeline cathodic protection systems states that The advantage of this technique is that potential mea-
“.... calculations of anode currents from current density surements are recorded at the same location during each
on electric field gradient measurements suffer from con- cathodic protection survey. Useful correlation of data
siderable errors such as those introduced when mea- from successive surveys is therefore possible. The ma-
suring the c.d/e.f.g., determining the sensor to anode jor limitation is that the reference electrode cannot be
distance and the direction of the measurement and fur- placed at specific locations, such as nodes or anodes.
thermore estimating the symmetry of the electric Despite this, the guy wire survey is an improvement over
field.”4 the drop line survey and can still be accomplished at a
relatively low cost. This is particularly true on structures
E.F.G. measurements are extremely useful for deter- located in shallow water.
mining location and relative severity of coating holidays,
and for locating disfunctional anodes. The measurements Diver/R.O.V. Assisted Platform Survey
can also provide a useful comparative estimate of an- This technique employs a diver or R.O.V. to position
ode outputs They do not provide highly reliable data the reference electrode near the structure. The poten-

Corrpro Companies, Inc. Technical Paper 4 Page 6 of 10


tial survey may be performed using one of two tech- pleted anodes or by metal unaccounted for in the ca-
niques. One technique involves use of a diver held volt- thodic protection design (e.g. debris, additional con-
meter equipped with a sharp metallic probe and a Ag/ ductors), then environmental conditions must be con-
AgCl reference electrode. The diver simply presses the sidered. These include temperature, dissolved oxygen,
contact probe against the structure and reads the digital salinity, and water currents. Each of these parameters
display of the voltmeter. The potential reading is trans- can be measured from the surface to the sea floor to
mitted to the surface by audio link provide a complete profile with depth.

The preferred method is to use an above water metallic The primary advantage of using a diver or an ROV to
connection to the structure and an above water mea- perform a platform potential survey is that the electrode
surement device. The diver or R.O.V. is used solely to can be placed at known locations, thus allowing a de-
place the reference electrode at the desired location tailed potential map of the structure to be obtained. This
while the potential measurement is recorded. This as- is the only method of assuring that cathodic protection
sures that a high resistance metallic contact is not af- is being achieved at all locations on the structure.
fecting the potential measurement.
The choice of using divers or ROV’s to perform the
If an R.O.V. is used, potential is measured using a sil- survey is primarily a function of water depth Generally,
ver/silver chloride reference electrode mounted on the ROV’s are more cost effective than divers for inspec-
frame of the vehicle. The electrode is mounted in a po- tions in over 200 feet of water. Otherwise, divers and
sition that allows the tip of the electrode to be placed ROV’s both have their attributes and drawbacks Divers
directly against the structure in front of the video cam- are capable of performing many functions such as mag-
era. netic particle inspection, cleaning, debris removal and
repairs far more effectively than ROV’s . The primary
The primary purpose of the survey is to obtain a com- advantage of ROV’s besides increased depth capabili-
prehensive potential profile of the platform. This is ac- ties, is as a relatively stable platform for video record-
complished by recording potential values around each ing. This allows the viewer on the surface, who is hope-
node and at all locations where cathodic protection cur- fully an experienced corrosion engineer, to direct the
rent flow may be shielded or otherwise impeded, such corrosion survey by watching a video monitor. The
as at conductor bell guides. Potential values are also placement of the electrode as well as any damage, cor-
recorded along representative structural members and rosion or debris is recorded on videotape. In most cases,
conductors. Special attention is given to areas of the inspection data such as depth, time, data and potential
jacket such as the skirt pile guides, conductors, and is digitally superimposed on the videotape. This aids in
boat docks post survey data processing, tape editing and report-
ing. Note that many operators are now using a combi-
Representative anodes should be visually inspected and nation of divers and ROV’s for comprehensive inspec-
tested for operation by structure-to-electrode poten- tions on major structures. ROV’s are generally used for
tial, electric field gradient, or both Where areas of lower the detailed potential survey and visual inspections, fol-
than expected potential values are detected, more ex- lowed by divers for marine growth removal, cleaning,
tensive testing is performed. This includes physical mea- NDT and debris removal.
surement of adjacent anodes, electric field gradient
measurements and detailed visual inspection. Platform EFG/Current Density Survey
Several major operators, particularly in the North Sea,
If low potential values are found over an entire depth regularly employ EFG/Current Density measurements
zone, further testing and inspection is performed. When as a component of comprehensive ROV assisted jacket
a visual inspection of the depth zone indicates that the inspections. The E.F.G. measurements are used to cal-
low potential values are not caused by missing or de- culate cathode current densities and anode outputs. This

Corrpro Companies, Inc. Technical Paper 4 Page 7of 10


data is useful in diagnosing current distribution prob- Most information management systems use personal
lems, estimating cathodic protection system life, and computers in conjunction with a relational data base
designing new and retrofit cathodic protection systems. system. Inspection information is generally entered into
the computer on board the survey vessel as the inspec-
These measurements are particularly useful for design tion proceeds. This information must include time, date,
of cathodic protection for deep water structures. Many videotape number and test point designation for corre-
cathodic protection design parameters for deep water lation with drawings, logs and videotapes. Inspection
are not well understood, although research is currently points, such as nodes, are each assigned an alphanu-
being conducted. EFG/Current Density measurements meric designation based on depths and structural loca-
on existing deep water structures provide valuable em- tion. This uniquely identifies each inspection point in the
pirical information for future designs. This includes an- data base for retrieval, editing and reporting.
ode performance, polarization rates and current den-
sity requirements. Additional information that may be entered includes the
following:
Due to the complex geometry of platform jackets, ac-
curate and useful EFG measurements require the use of * Potentials
highly sophisticated EFG sensors. These EFG measure- * EFG
ment systems must be able to detect changes in poten- * Debris-type, size
tial in the micro-volt range and have the means for de- * Structural damage-type, description
termining the direction of current flow. Several ROV * Corrosion-type, severity
mounted systems are currently being used. These in- * Scouring-bottom survey
clude the rotating T-sensor described earlier, and a sen- * Marine Growth-thickness, type, % of coverage
sor containing a concentric array of several reference * Work Description
electrodes all referenced to a common central electrode.
This data is stored in the database for subsequent analy-
EFG measurements are generally recorded at repre- sis and generation of inspection reports. These inspec-
sentative anodes, nodes, conductors and pile guides. tion reports are used for trend analysis, creation of re-
The data is later used to calculate current densities and pair work orders, corrosion data evaluation and main-
anode outputs. In some cases, the EFG data is used tenance scheduling and budgeting. An example of a typi-
along with potential data for calculation of current dis- cal report menu is as follows:
tribution using computer modeling techniques such as
finite element and finite boundary analysis. * Inspection Log
* Test Points not inspected
Computerized Inspection Data Management * Cathodic Protection Potentials outside limits
During a comprehensive inspection of a platform jacket, * Potential History
vast amounts of pertinent data are collected. This may * Debris Survey
include cathodic protection potentials, EFG measure- * Structural Damage Survey
ments and descriptions of marine growth, debris and * Strructure Inspection Summary
structural damage. Additionally, hours of videotape are * Repair Status
recorded. In the case of a diver assisted inspection, the * Photograph Log
data may include magnetic particle inspection and ultra
sonic testing. Computerized data management systems More sophisticated data base management systems uti-
have been developed to facilitate accurate and com- lize CAD technology to graphically recreate the struc-
plete information recording, compilation, analysis and ture on the computer screen. These graphic capabilities
reporting. are useful for detailed visual identification of anomalies
such as cracks, repairs, or corrosion, as well as for

Corrpro Companies, Inc. Technical Paper 4 Page 8 of 10


sketches for bidding, data analysis and 5 creating re- lations of P/E based on remote electrode measurements
porting. is also an acceptable method assuming that direct con-
tact P/E potential measurements are made at frequent
The ultimate aim of computerized data management distance intervals. Calculations of P/E potential based
systems is to aid the inspection manager in efficient plan- on EFG measurements is the least desirable method of
ning and operation of inspections, and to allow rapid obtaining a P/E potential profile.
analysis and reporting of results. Use of these systems
should increase as the importance of comprehensive B. Structure
inspection programs is recognized, and as acceptance 1. Drop line and guyline surveys provide general infor-
and knowledge of computer technology continues to mation on the potential levels of protected structures.
increase. The guyline is preferred since trends can be detected
by comparison with surveys of prior years. Neither tech-
CONCLUSIONS nique assures placement of the reference electrode in
All of the survey methods have been used extensively the most critical areas such as nodes.
and are constantly being modified and improved. The
choice of the method, or a combination of methods, is 2. Diver/ROV assisted surveys provide more detail for
dependent on a wide range of factors including water evaluating the effectiveness of cathodic protection sys-
depth, water currents, location, depth of burial, size or tems. Potential readings can be taken in the critical ar-
length, cathodic protection system age, and cost. The eas such as nodes or conductor bays. Visual inspec-
requirements of each individual pipeline or structure will tion assists in determining the cause of any problems
help dictate the method to be used. In general, the fol- detected. To prevent inaccurate measurements and the
lowing guidelines are offered: need for call backs, an experienced corrosion engineer
should be present for on site data interpretation. This
A. Pipeline will ensure proper equipment calibration and additional
1. For measurement of overall P/E potential and loca- investigation where initial measurements indicate poten-
tion of major problem areas, the towed vehicle method tial problem areas. ROV assisted platform surveys are
is far and away the most economical, particularly for the most economical and effective for deep water plat-
long pipelines. If problem areas are discovered using forms. In addition to structure-to-electrolyte potentials,
the towed vehicle method, then a submersible survey EFG measurements can be recorded. The video moni-
should be used to obtain detailed information on those tor provides a permanent record of the measurements
sections. and location. Again, the use of experienced vehicle op-
erators and corrosion engineers is necessary to achieve
2. For completely buried pipelines, the towed vehicle the best results.
method is the most reliable for obtaining the P/E poten-
tial profile. Pipe tracking devices can be fitted to 3. Computerized information management systems are
submersibles, but because of the separation between a valuable tool for the inspection manager. These sys-
the electrode and pipe caused by burial, submersible tems, designed for use with personal computers, pro-
assisted measurements may not be significantly more vide the basis for rapid and accurate data acquisition,
sensitive or accurate. analysis and reporting. The reports are designed to aid
in inspection and repair budgeting, bidding and sched-
3. To obtain detailed information concerning relative uling. The most advanced systems utilize CAD technol-
output of anodes, size and location of coating flows, ogy for graphic display of jacket components and in-
and integrity of field joint wraps, electric field gradient spection results. These systems can facilitate exact lo-
measurements are most effective, particularly when used cation of anomalies as well as provide sketches for bid-
in conjunction with either the submersible P/E potential ding or reporting purposes.
survey or direct contact P/E potential readings. Calcu-

Corrpro Companies, Inc. Technical Paper 4 Page 9 of 10


REFERENCES

1. Weldon, C.P. and Weldon, F.C., “Methods for Moni-


toring Effectiveness of Cathodic Protection on Offshore
Pipelines”, paper presented at the Middle East Corro-
sion Conference, Bahrain, May, 1983.

2. Weldon, C.P. and Wolfson, S.L., “The Submersible


Assisted Offshore CPLtmm Survey Method”, paper
presented at South Central Regional N.A.C.E. meet-
ing, Corpus Christi, Texas, October 5, 1982.

3. Corrocean, corporate engineering brochure (prod-


uct and service description), Trondheim, Norway, 1987.

4. Sydberger, Thomas, “Evaluation of Inspection Meth-


ods for Offshore Pipeline Cathodic Protection Systems”,
Det Norske Veritas (1982).

5. Ocean Systems Engineering, Inc., CAIRS product


description and brochure, Houston, Texas, 1987.

Corrpro Companies, Inc. Technical Paper 4 Page 10 of 10

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